GEAR- Gears are used to transmit motion from one shaft to another or between a shaft and a

slide. This is accomplished successively engaging teeth.

Gears use no intermediate link or connector and transmit thee motion by direct contact. The two
bodies have either a rolling or a sliding motion along the tangent at the point of contact. No motion
is possible along the common normal as that will break th contact or one body will tend to penetrate
into the other.

LAW OF GEARING- The fundamental law of gearing states that the angular velocity ratio
between the gears of a gear set must remain constant throughout the mesh. 

 ω1/ ω2=r2/r1=constant

In order to maintain this constant angular velocity ratio between two meshing gears, the common
normal of the tooth profiles, at all contact points within mesh, should always pass through a fixed
point on the line of centres, called pitch point.

DIFFERENT TYPES OF GEARS-

Spur gears have straight teeth and are parallel to the axis of the wheel. Spur gears are the most
common type of gears. The advantages of spur gears are their simplicity in design, economy of
manufacture and maintenance, and absence of end thrust. They impose only radial loads on the
bearing.

spur gears

2)     Helical Gear-Helical gears have their teeth inclined to the axis of the shafts in the form of a
helix, hence the name helical gears.
These gears are usually thought of as high speed gears. Helical gears can take higher loads than
similarly sized spur gears. The motion of helical gears is smoother and quieter than the motion of
spur gears.
 Helical gear

3)  Bevel Gear-Intersecting but coplanar shafts connected by gears are called bevel gears. This
arrangement is known as bevel gearing. Straight bevel gears can be used on shafts at any angle, but
right angle is the most common. Bevel Gears have conical blanks. The teeth of straight bevel gears
are tapered in both thickness and tooth height. 

  Bevel gear
4)      Worm Gear- Worm gears are used to transmit power at 90° and where high reductions are
required. The axes of worm gears shafts cross in space. The shafts of worm gears lie in parallel
planes and may be skewed at any angle between zero and a right angle. In worm gears, one gear has
screw threads. Due to this, worm gears are quiet, vibration free and give a smooth output. Worm
gears and worm gear shafts are almost invariably at right angles.

Worm gear

5)      Rack and Pinion- A rack is a toothed bar or rod that can be thought of as a sector gear with an
infinitely large radius of curvature. Torque can be converted to linear force by meshing a rack with a
pinion: the pinion turns; the rack moves in a straight line. Such a mechanism is used in automobiles
to convert the rotation of the steering wheel into the left-to-right motion of the tie rod.

Rack and pinion

GEAR GENERATION
In gear form cutting, the cutting edge of the cutting tool has a shape identical with the shape of the
space between the gear teeth. Two machining operations, milling and broaching can be employed to
form cut gear teeth.

In gear generating, the tooth flanks are obtained (generated) as an outline of the subsequent
positions of the cutter, which resembles in shape the mating gear in the gear pair:

In gear generating, two machining processes are employed, shaping and milling. There are several
modifications of these processes for different cutting tool used,

 Milling with a hob (gear hobbing),

Cutters and blanks rotate in a timed relationship: a proportional feed rate between them is
maintained.

Gear generating is used for high production runs and for finishing cut.
GEAR MANUFACTURING-
Gear manufacturing refers to the making of gears. Gears can be made by a variety of processes,
including casting, forging, extrusion, powder metallurgy and blanking. As a general rule, however,
machining is applied to achieve the final dimensions, shape and surface finish in the gear. The initial
operations that produce a semi-finished part ready for gear machining as referred to as blanking
operations: the starting product in gear manufacturing is called a gear blank.

The various production methods for producing the gears by machining are as follows:

 Gear Hobbing
 Gear Planning
 Gear Shaping

We are mainly concern about gear hobbing process.

GEAR HOBBING
Hobbing is a machining process for a gear cutting, cutting splines, and cutting sprockets on a hobbing
machine, which is a special type of milling machine. The teeth or splines are progressively cut into a
work-piece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming
processes, it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts
and quantities.

When bobbing a spur gear, the angle between the hob and gear blank axes is 90° minus the lead
angle at the hob threads. For helical gears, the hob is set so that the helix angle of the hob is parallel
with the tooth direction of the gear being cut. Additional movement along the tooth length is
necessary in order to cut the whole tooth length.

The hob and the gear blank are connected by a proper gearing so that they rotate in mesh. To start
cutting a gear, the rotating hob is fed inward until the proper setting for tooth depth is achieved,
then cutting continues until the entire gear is finished.

HOB-
The hob is a cutting tool used to cut the teeth into the work-piece. It is cylindrical in shape with
helical cutting teeth. These teeth have grooves that run the length of the hob, which aid in cutting
and chip removal. There are also special hobs designed for special gears such as the spline and
sprocket gears.

The cross-sectional shape of the hob teeth are almost the same shape as teeth of a rack gear that
would be used with the finished product. There are slight changes to the shape for generating
purposes, such as extending the hob's tooth length to create a clearance in the gear's roots.
Each hob tooth is relieved on the back side to reduce friction.

Gear Hob

Most hobs are single-thread hobs, but double and triple-thread hobs increase production rates. The
downside is that they are not as accurate as single-thread hobs. Depending on type of gear teeth to
be cut, there are custom made hobs and general purpose hobs. Custom made hobs are different
from other hobs as they are suited to make gears with modified tooth profile. The tooth profile is
modified to add strength and reduce size and gear noise.

Procedure:
The hob is set at an inclination equal to the helix angle of the hob with the vertical axis of the blank.
If a helical gear is to be cut, the hob axis is set at an inclination equal to the sum of the helix angle of
the hob and the helix angle of the helical gear. Proper gear arrangement is used to maintain rpm
ratio of gear blank and hob. The operation of gear hobbing involves feeding the revolving hob till it
reaches to the required depth of the gear tooth. Simultaneously it is fed in a direction parallel to the
axis of rotation.

Three important parameters are to be controlled in the process of gear hobbing are:

 Indexing movement.
 Feed rate.
 Angle between the axis of gear blank and Gear hobbing tool (gear hob).

ADVANTAGES-
 It is versatility to produce a variety of gears including Spur, Helical, Worm Wheels,
Serrations, Splines, etc. 
 It has higher productivity rate as compared to other methods.
 It is an economical and efficient operation.
 Accuracy is high.
 Close tolerances can be maintained under this procedure.
 Excellent surface finish is obtained.

Apart from these advantages there is one major limitation of this process that is manufacturing of
internal gears is not possible.
FORMULA USED-
DP = (N+2)/OD

OD=outer diameter

DP=1/M, M=module , N=number of teeth , DP=Diametrical pitch

PCD=OD-2*Addendum=Pitch Circle Diameter

M=PCD/T

Results and Calculations:

Dedendum = 1*M

N=47

OD= (49/14) ==3.5 inch

DP=14

Calculated chordal thickness = π*OD/2N =0.117inch

Observed chordal thickness=0.108 inch